3-series

It's been a long time coming since we last left off with the development of this intercooler. While it might have been trying on your patience, and a little on ours, it's not necessarily a bad thing that it took some time. Simply put, how are we going to make sure that what ends up at your door step is perfect if the first doesn't possess the same qualities? And sometimes doing things a little differently takes some time.

If you look back to our last post outlining the design plans, you'll see exactly what I'm on about when it comes to doing things differently. We did end up giving a good amount away then, but since it's been a while, I'll refresh your memory.

Yes, the stepped core is nothing new nowadays. With the F2X and F3X Bimmers, the design of the stock system almost requires a stepped core in order to squeeze more performance out of the N55 and N20 engines. During our development process, we investigated the idea of a few other core configurations, but neither quite stacked up to

When I last left off our engineer, Steve, was busy scanning and creating a 3D model of the F30 stock unit as a reference for our new design. There is an impressive amount of engineering that has gone into this intercooler project already, with more to come. One of the reasons for this attention to detail is because of the wide range of models that this new cooler is going to fit, as seen by our photo gallery. Another reason is because BMW has a pesky habit of living up to their moniker, "The Ultimate Driving Machine," they leave little room for error.

Steve working the Faro Design ScanArm to create a 3D model of the stock intercooler unit.

I've always been a huge fan of BMW, especially when it comes to the meticulous engineering that goes into each of their vehicles. Every model they put out is designed to last. Whether it be a 28-year old 3-series speeding around the flat back roads of New Jersey, or the much bigger and heavier X3 taking on the winding mountain roads of the Colorado

The pre-sale for this kit is now live! Click here to buy the Mishimoto N55 Catch Can Kit!

Nothing ruins a weekend drive through your favorite back roads more than an unexpected check engine light (CEL). That is, nothing except a flashing check engine light.  Having driven my fair share of Volkswagens, Audis, and more recently Subaru's, I've become quite accustomed to the warm, orange glow of a lit check engine light.  A solid CEL is something that no longer worries me; it's something that I, and most people who modify cars, have come to expect every now and then.  What does still haunt my dreams, however, is the flashing CEL. What's the difference? A solid CEL is usually a fault that's not life-threatening to the engine.  Small issues like loose fuel caps, small vacuum leaks, and dirty throttle bodies all cause a solid CEL. But what causes a flashing CEL is something much more dangerous: a major misfire.

The Orange Omen

The dreaded flashing check-engine light is a sign that something

During the development of our new intake system for the 1999-2005 BMW 3-series, we identified yet another component that would be a vital upgrade as the E46 chassis begins to age (gracefully though, right?). With a lack of support in offerings for a silicone E46 intake boot set, we decided to design a set that would replace the failure-prone stock rubber units. If you've ever owned a BMW (E30, E36, E46, etc.) that utilizes such rubber intake elbows and hoses, you may have experienced failure at some point. Typically the area of flex begins to develop cracks and tears over time. The unmonitored air entry results in a rough running straight-six " not exactly ideal. So let's get to the project!

Stock Intake Boots

First, check out the factory-equipped boots!

Stock BMW E46 intake boot assembly

Stock BMW E46 intake boot assembly

Stock BMW E46 intake boot assembly

The stock E46 intake boot uses a two-piece unit with three individual ports. The two-piece design allows for easier installation.

3D

Interested in picking up our E46 intake system? Check out our product page for more information!

Mishimoto BMW E46 Performance Air Intake

Final Intake Images

With successful testing data acquired from our first prototype, it was time to make a final prototype and perform our last test fit before producing a batch of final intake systems. Check out a shot of the shroud, intake hose, and filter!

Mishimoto E46 air intake shroud, intake hose, and air filter

The airbox is constructed of powder-coated steel, and we line the edges with weather stripping to prevent any vibrations or damage. The silicone coupler is a four-ply unit designed specifically for this kit.

The air filter shown above is the Mishimoto Oiled Air Filter. These filters are completely serviceable and can provide a lifetime of service if appropriately cleaned and maintained.

We also designed an internal CNC-machined connector that will allow the silicone intake hose to mate properly with our air filter. This setup can be seen

Interested in picking up our E46 intake system? Check out our product page for more information!

Mishimoto BMW E46 Performance Air Intake

After completing our initial prototype it was time to strap this E46 to the dyno and make a few pulls. We would be evaluating power output, monitoring vital engine sensors such as AFR, and collecting sound clips for comparison against the stock intake system.

Dyno Testing

E46 on dyno for intake testing

E46 on dyno for intake testing

E46 on dyno for intake testing

Time to make some pulls! Check out the dyno video below.

Initial Impressions

The video shows the changes our setup made in  intake noise. This is likely a result of our open-element filter residing within the engine bay. Although closing the hood seals off the airbox portion of the intake, it is still more audible than the stock unit. The stock airbox is designed in a way to reduce noise and create a more drivable experience for non-enthusiasts. That said, this creates a numbness among car